Support member sleeve

ABSTRACT

A shelter assembly has a framework having a plurality of structural supports that include fillable support tubes and support sleeves. The fillable support tubes may be filled with fill media and are surrounded by the support sleeve. The structural supports are configured to form a structure wherein the structural supports form the framework of the structure. Various fill media may be used. The structural supports and their associated assemblies are modular and may be configured into a variety of shelter designs.

PRIORITY AND RELATED APPLICATIONS

This application claims priority from provisional patent application Ser. No. 61/890,741 filed on Oct. 14, 2013, which is hereby incorporated by reference in its entirety. This application is related to patent application Ser. No. 13/474,123 filed on May 17, 2012, which is hereby incorporated by reference in its entirety.

BACKGROUND

The disclosure relates to building structures and support members used to construct building structures. More particularly, it relates to a method and an apparatus for building temporary or permanent structures, including, for example, structures for use as shelters.

There are many instances where a temporary structure is needed to provide shelter. For example, natural disasters such as hurricanes, tornadoes, tsunamis, earthquakes and floods often render thousands of people homeless, either temporarily or permanently. Oftentimes, victims of such disasters need shelter, at least on a temporary basis. Tents are often used for shelters, but are not very stable or durable and can only be used for a short duration of time. Tents also do not always provide adequate shelter from the elements, such as rain, snow or excessive heat or cold. Tents also are not effective at providing insulation. In addition, large tents require large, long support members that are difficult to transport, and require a team to assemble. Further, most tents do not have interior partitions and are not able to be reconfigured to be suitable for a multitude of different uses.

Thus, it is desirable to provide a structure which is easy to assemble and disassemble, and which can provide an insulated shelter which is sturdy and durable can be used for either a short-term or long-term basis.

The structure can be used for other various applications, including, for example, during military operations, homes for third world countries or homeless people, etc.

Thus, there is a need for temporary or permanent structures which overcome the above-mentioned deficiencies and others, while providing improved overall results.

SUMMARY

According to one embodiment, a structural support for a shelter assembly includes a support sleeve and at least one fillable support tube inserted within the support sleeve.

The descriptions of the invention do not limit the words used in the claims in any way or the scope of the claims or invention. The words used in the claims have all of their full ordinary meanings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to exemplify embodiments of this invention and highlight the functional modality of the invention, including any methods.

FIG. 1 illustrates a perspective view of an exemplary shelter assembly;

FIG. 2 illustrates a perspective view of another exemplary shelter assembly;

FIG. 3 illustrates a perspective view of another exemplary shelter assembly;

FIG. 4 illustrates a perspective view of an exemplary fillable support tube in an unfilled state;

FIG. 5 illustrates a perspective view of an exemplary fillable support tube in a filled state;

FIG. 6 illustrates a perspective view of another exemplary fillable support tube in a filled state;

FIG. 7 illustrates an exemplary cross-section of a tube filled with polyurethane (PU) foam;

FIG. 8 illustrates a perspective view of an exemplary support sleeve;

FIG. 9 illustrates a perspective view of an exemplary structural support during assembly;

FIG. 10 illustrates a perspective view of an exemplary structural support after assembly;

FIG. 11 illustrates a perspective view of another exemplary structural support during assembly;

FIG. 12 illustrates a perspective view of another exemplary structural support after assembly;

FIG. 13 illustrates a perspective view of another exemplary fillable support tube in an unfilled state;

FIG. 14 illustrates a perspective view of another exemplary fillable support tube in a filled state;

FIG. 15 illustrates a perspective view of another exemplary fillable support tube in a filled state;

FIG. 16 illustrates a perspective view of another exemplary structural support during assembly;

FIG. 17 illustrates a perspective view of another exemplary structural support after assembly;

FIG. 18 illustrates a perspective view of an exemplary column/header assembly in an unfilled state;

FIG. 19 illustrates a perspective view of an exemplary column/header assembly in a filled state;

FIG. 20 illustrates a top view of an exemplary set of support sleeves in a flat state;

FIG. 21 illustrates a top view of an exemplary set of fillable support tubes on top of a set of support sleeves;

FIG. 22 is a block diagram of an exemplary media delivery system;

FIG. 23 illustrates a top view of another exemplary set of fillable support tubes on top of a set of support sleeves;

FIG. 24 illustrates a side view of an exemplary hall assembly;

FIG. 25 illustrates a side view of the hall assembly with a plenum inlet extending through the hall assembly;

FIG. 26 illustrates a perspective view of an exemplary HVAC plenum; and

FIG. 27 is a line graph comparing test results from four sections of support tubes, with and without a support sleeve.

DESCRIPTION OF EMBODIMENTS

FIG. 1 illustrates a perspective view of an exemplary shelter assembly 100, which may be a temporary or permanent structure for providing shelter. The shelter 100 includes various modular assemblies and components, including, roof assemblies 102, wall assemblies 104, hall assemblies 106, and columns 108. The various assemblies of the shelter 100 may include sheeting 110 wrapped around and/or connecting various structural supports of the assemblies, including in the form of a tarp or cover. The dashed lines in FIG. 1 represent where structural supports, including columns, are located behind the sheeting 110.

The structural supports are used to provide the framework to construct the shelter 100. The structural supports may be used for the framework of the assemblies 102, 104, 106 and columns 108. The structural supports typically include a support sleeve surrounding a fillable support tube. The combination of support sleeves and fillable support tubes, which can utilize foam, gas, water, and/or any other appropriate fill media, provide strength, insulation, rigidity, etc. for the shelter 100, as discussed in detail below. The structural supports are generally modular, durable, lightweight, easily assembled/disassembled, and easily filled (and in some embodiments, easily deflated). In this embodiment, the exemplary shelter 100 is formed with four modular units 130 and two hall assemblies 106. Hall and/or wall assemblies may include internal header sections (not shown) that provide internal support and can also be used to partition the inside area into various rooms. In other embodiments, any number of modular units 130 (configured using a variety of wall, roof, and header assemblies) and/or hall assemblies may be connected together to form any size and configuration of shelter suitable for a particular application.

The various assemblies of the shelter 100 may also include various other features common to structures, including, for example, windows 112, man doors 114, cargo doors, skylights, exhaust/intake vents, heating and cooling pipes/ducts/plenums, electrical and communication services, conduits, chutes, etc. In one embodiment, the windows 112 are constructed from clear sheeting and the man doors 114 are constructed using the same sheeting as the shelter sheeting 110. In various embodiments, the windows 112 may be fixed, hinged, and/or detachable, including, for example, using a zipper or hook-and-loop type fastening (e.g., Velcro® straps). The man doors 114 may also be hinged, and/or detachable, including, for example, using a zipper or hook-and-loop type fastening. In some embodiments, doors, windows, and/or other features may open with a zipper or similar device that is attached to the structure with hook-and-loop fasteners or a similar detachable mechanism, such that if the zipper fails, it can be quickly replaced.

It should be appreciated that the various modular assemblies of the shelter 100, including, roof assemblies 102, wall assemblies 104, hall assemblies 106, and columns 108 may be configured in any number of ways, including, for example, the heights, widths, and lengths of all components (including structural supports), roof pitches, window 112 placement, door 114 placement, etc. The modular assemblies may be combined to create any size and configuration of shelter suitable for a particular application. Expansions to existing shelters are accomplished by adding to the existing assemblies. In other embodiments, the modular assemblies and structural supports may be disassembled and reused in another shelter.

The sheeting 110 and the structural supports (including support sleeves and support tubes) may be constructed using any suitable material for a particular and/or multiple applications. For example, in one embodiment, if the structure is deemed for use as a short-term and/or disposable shelter, the sheeting 110 and/or structural supports may be fabricated from one or more different materials, such as, for example, high density polyethylene, polyvinyl chloride (PVC), plastic, fabric, cloth, mesh, coated mesh, vinyl coated fabric (e.g., Bondcote® H13-645), or any other suitable material types. The material can be thin sheets, such as, for example, 2 mil thickness to 6 mil thickness (i.e., 0.002 to 0.006 inches thick), or any suitable thickness or shape. In another embodiment, if the structure is intended to be used for a long-term application, such as, for example, about two years or more, then a longer lasting and more durable material, such as, for example, vinyl-coated polyester or nylon cloth or any other suitable material may be used.

The shelter 100 may also incorporate features and materials used in conventional structures, including, for example, wood, metal, glass, solid ducts, wiring, conduit, flooring, decking, etc. For example, in one embodiment, the sheeting 110 and all of the structural supports may be constructed using a flexible material, such as, for example, plastic, fabric, cloth, mesh, coated mesh, vinyl coated fabric (e.g., Bondcote® H13-645), etc.

The sheeting 110 may also incorporate a variety of colors and/or material properties, including, for example, colors and materials that may or may not be easily visible, reflective, and/or exhibit thermal signatures. In different embodiments, it may be desirable for the shelter 110 to be easily visible, including using thermal imaging or it may be desirable for the shelter 110 to be camouflaged, both visibly and thermally, using various materials.

In some embodiments, the sheeting 110 may be modularly associated and/or installed with each assembly, including, for example, roof assemblies 102, wall assemblies 104, hall assemblies 106, etc. In these embodiments, the sheeting 110 may include various flaps for overlapping and/or securing with neighboring assemblies. In other embodiments, the sheeting 110 may be installed after assembly of the various assemblies in larger sections, resulting in less seams. The use of flaps and/or larger sheets of sheeting 110 may also be used to provide additional strength and rigidity to the shelter 100 and/or for better weather protection, including, for example, to prevent water intrusion, act as flashing, prevent air drafts, etc.

FIG. 1 also shows flaps 116 along the ground extending outward from the bottom of the wall assemblies 104. In other embodiments, these flaps 116 may extend inward under the wall assemblies 104. These flaps 116 may be used to secure the shelter 100 to the ground, flooring, decking, etc., including using various fasteners, such as, for example, stakes. In one embodiment, sand bags and/or other heavy materials may be placed on top of the flaps 116 to secure the shelter 100 in place. In some embodiments, the flaps 116 may be nailed to a deck or floor. These flaps may also be incorporated into the sheeting 110.

In other embodiments, including, for example, high-wind applications, the shelter 100 may also be secured to the ground using wires, cables, ropes, etc. attached to the flaps 116, roof assemblies 102, wall assemblies 104, hall assemblies 106, and/or columns 108. In one embodiment, strapping may be used in conjunction with the structure to secure the structure to the ground or to secure a covering over the structure. For example, eyelets can be added to various positions in the shelter 100 to allow a rope or cable to secure the shelter 100 against high winds, gusts, rain, etc. Eyelets can also be placed flush to the ground so stakes can be used adjacent to the assemblies and/or structural supports.

The sheeting 110 may be installed on one or both sides of the various assemblies 102, 104, 106. The configuration of sheeting 110 in these embodiments may be based on a number of factors, including, for example, insulation, strength, privacy, security, cost, etc. Multiple types of sheeting 110 may be used in the same application. In embodiments with sheeting 110 on the inside and outside of the assemblies, the cavities created between the sheeting 110 layers may be filled with materials that may provide additional and/or enhance the insulation, strength, privacy, security, etc. properties of the shelter 100. For example, in one embodiment, fibrous or foam insulation may blown into the wall and/or roof cavities.

FIG. 2 illustrates a perspective view of an exemplary shelter assembly 200, which may be used as a stand-alone shelter or as part of a larger shelter, including, for example shelter 100. In this embodiment, shelter 200 includes a roof assembly 202, a wall assembly 204 without a window, a wall assembly 206 with a window 208, and an interior layer of sheeting 210. FIG. 2 also shows various flaps 212 made of plastic, fabric, cloth, mesh, coated mesh, vinyl coated fabric (e.g., Bondcote® H13-645), and/or other suitable materials, which are folded and/or wrapped around over mating structural supports and columns, and may act as flashing. The flaps 212 can be covered with hook-and-loop straps or any other suitable fastening means which securely fasten to corresponding surfaces on the mating components.

FIG. 2 also shows various exemplary straps 214 made of hook-and-loop or other suitable fastening means which securely fasten one structural support to another. Straps 214 may be utilized wherever one structural support meets another structural support and/or other corresponding surfaces or mating component, although not shown in FIG. 2. In the embodiment of FIG. 2, the flaps 212 are covering various other locations of straps 214 fastening one structural support to another structural support, including, for example, where the roof assembly 202, wall assemblies 204, 206, and columns (also covered by flaps 212) meet.

In various embodiments, any number and configuration of flaps 212 and/or straps 214 may be used to secure various assemblies together. The flaps 212 and/or straps 214 may also be used for attaching center wall sections to the frame structure.

Other reinforcements may also be used in the shelter 200, for example, to provide for modularity, ease of assembly, additional strength, etc. For example, a floor panel 216 made be used under a column to provide additional support, strength, and/or attachment surfaces. In one embodiment, the floor panel 216 can matingly receive a lower portion of a column. In different embodiments, the floor panel 216 may be constructed with lightweight sheeting-type materials or heavier materials, such as, for example, various metals, to provide anchor points for the shelter 200.

FIG. 3 illustrates a perspective view of another exemplary shelter assembly 300, which may be used as a stand-alone shelter or as part of a larger shelter, including, for example shelter 100. In this embodiment, shelter 300 includes a roof assembly 302, columns 306, and a plurality of wall assemblies 308 removably connected to the roof assembly 302 and columns 306. The roof assembly 302 includes structural supports 304. In this embodiment, the roof assembly 302 is installed onto four columns 306 by inserting the columns 306 into coupling or connecting members 324 as shown in FIG. 3. Connecting members 324 can be formed of plastic, fabric, cloth, mesh, coated mesh, vinyl coated fabric (e.g., Bondcote® H13-645), or other material and extend over an upper portion of a column 306 in a covering or sock-like fashion.

Once the roof assembly 302 is installed on the columns 306, wall assemblies 308 are installed between adjacent columns 306. Wall assemblies 308 may be formed by a plurality of structural supports 310. Sheeting, such as panels 312, may be made of plastic, fabric, cloth, mesh, coated mesh, vinyl coated fabric (e.g., Bondcote® H13-645), or any other suitable material, and may be selectively installed between structural supports 310 on the outside or inside of the structural supports 310. Window openings 314 and door openings 316 may be formed between support members 310. The wall assemblies 308 may be interchangeable and are replaceable as needed. The structural supports 304, 310 may include a support sleeve surrounding one or more fillable support tubes, which can be filled with foam, gas, water, and/or any suitable material, as discussed in more detail below.

Straps 330 with any other suitable fastening means such as hook-and-loop (e.g., Velcro®), clips, hooks, buttons, etc. can be attached to structural supports 304, 310 and/or columns 306 to removably secure the roof assembly 302, wall assemblies 308, and columns 306 together. Similar straps 340 may be attached to structural supports 304, 310 to removably secure the roof assembly 302 and wall assemblies 308 together. Flaps (not shown, such as flaps 212 shown in FIG. 2) may also be secured to the structural supports 304, 310 and/or columns 306 to overlap and/or join the roof assembly 302, wall assemblies 308, associated sheeting, columns 306, etc. together.

As mentioned above, the structural supports (such as, e.g., 304, 306, 310 shown in FIG. 3) are used to provide the framework to construct the shelter (such as, e.g., shelters 100, 200, 300 shown in FIGS. 1-3). The structural supports may be used for the framework of the various assemblies and columns (such as, e.g., 102, 104, 106, 108, 202, 204, 206, 302, 306, 308 shown in FIGS. 1-3). The structural supports typically include a support sleeve surrounding one or more fillable support tubes. The fillable support tubes can utilize foam, gas, water, and/or any other appropriate fill media to provide strength, insulation, rigidity, etc. for the shelter. The structural supports are designed to be modular, durable, lightweight, and easily assembled or disassembled and easily replaced if damaged without affecting the integrity of the shelter.

A structural support may include any number of support sleeves and fillable support tubes. For example, in one embodiment, a structural support may include one straight sleeve with one or more fillable support tubes. In another embodiment, a structural support may be configured as an entire assembly (e.g., a sleeve assembly for use in a roof or wall assembly) that includes a plurality of interconnected sleeves, each with one or more fillable support tubes, as discussed in more detail below.

FIG. 4 illustrates a perspective view of an exemplary fillable support tube 400 in an unfilled state. In this embodiment, tube 400 includes a tube wall 402 constructed of plastic, fabric, cloth, mesh, coated mesh, vinyl coated fabric (e.g., Bondcote® H13-645), thermoplastic, polyethylene, PVC, or any plastic or rubber similar to that used for inflatable rafts or thicker plastic such as that used for tarps. The tube wall material, as well as any other material described herein, including, for example, sheeting, sleeves, etc., may be selected based on the strength and performance requirements of a particular application. For example, higher strength fabric will result in higher strength support tubes, support sleeves, sheeting, etc. The tube wall 402 may be of various thicknesses and can be flexible, rigid, or include portions with more or less rigidity than others. For example, in one embodiment, the tube wall 402 may include generally flexible plastic material along with rigid members (i.e., stiffeners) (not shown) extending lengthwise and imbedded or attached around the periphery of the tube 400.

Tube 400 may also include an exemplary fill port 404 and an exemplary sight window 406. The fill port 404 is where the fill media is injected into the tube 400 using, for example, a media dispensing tool. Some embodiments may include tubes 400 that have multiple fill ports 404. The fill port 404 may be made from any suitable material and be of any design suitable for the fill media and/or dispensing tool. The fill port 404 may include an open/close mechanism, such as, for example a plug 405. In other embodiments, the fill port 404 may include one or more valves, including, for example, check valves to prevent media from escaping the tube 400. By filling the tube 400 with media, the tube (and its associated structural support, as discussed below) may have additional rigidity and stiffness, additional structural strength, maintain its shape better, and/or act as an insulator. In some embodiments, different tubes 400 may be filled with different media or no media at all.

The sight window 406 is used to view the progression of the media inside of the tube 400 as it fills the tube 400 from the fill port 404. Some embodiments may include tubes 400 that have multiple sight windows 406. The sight window 406 may be made from any suitable material for viewing the inside of the tube 400 and may be integrated into the tube wall 402. In some embodiments, the sight window 406 may incorporate a sensing or indicator feature to alert the user of the presence of the fill media at the window 406. In one embodiment, for example, the window 406 may change color in response to contact with the fill media. The tube 400 may be filled with various media, including, for example, water, gas, foam, etc. Alternatively, in other embodiments, the tube 400 can be sufficiently rigid and of sufficient thickness of plastic to not need to be filled. In other embodiments, the media dispensing apparatus may be attached to or include a timer to control the amount of media injected into the tube 400. In these embodiments, the sight window 406 may be optional.

The tube 400 may be manufactured using any suitable process, including one-piece and multi-piece designs. For example, the tube 400 may be formed, for example, using a molding or blow-molding process, in a one-piece manner (e.g., like a balloon), wherein the fill port 404 may be placed at the molding feed or vent. In other embodiments, the tube 404 may be formed, for example, using stitching, bonding, gluing, welding, and/or staking processes, from multiple pieces, wherein a seam is formed where the pieces are overlapped and joined.

In one embodiment, as shown in FIG. 4, the tube 400 is designed to be filled with an expandable foam, such as, for example, polyurethane (PU) expandable foam using, for example, a dispensing gun with an integrated mixing device to blend the two-part foam chemicals constituting the foam immediately before injecting them into the tube 400. In another embodiment, the mixing device may be included in the fill port 404. Various other foams, including, for example, one-part foams, other closed cell and open cell foams, with varying expansion rates, strengths, cure times, etc. may also be used.

The locations of the fill port 404 and the sight window 406 may be determined based on the particular application and fill media. For example, in this embodiment, the locations of the fill port 404 and the sight window 406 are determined based on the expansion properties of the exemplary PU foam. In particular, the locations of the fill port 404 and the sight window 406 are determined such that when a user sees the expanding foam progress to the sight window 406, the user stops injecting foam into the tube 400 at the fill port 404. In this manner, the tube 400 fills completely with the PU foam without any substantial voids/empty pockets or overfilling.

In this embodiment, the exemplary PU foam, when mixed, produces carbon dioxide (CO₂) gas, which may form bubbles within the foam. The goal is to fill the tube 400 completely with media (e.g., PU foam), without voids. The tube wall 402 of the tube 400 helps restrict foam expansion and the forming of air or gas voids. In some embodiments, a propellant may be used to quickly mix and move the PU foam into and throughout the tube 400 quickly, which may also assist in minimizing the formation of bubbles or voids.

With continued reference to FIG. 4 and with further reference to FIGS. 5-6, which show the exemplary fillable support tube 400 in a filled state, the tube 400 may also include a vented end 408 and a fill end 410. The vented end 408 and/or the fill end 410 may be made from any suitable material, including the material used to construct the tube wall 402. The vented end 408 may also include a vent 412 that allows gas to escape from the tube 400 as the fill media is filling and/or curing in the tube 400. However, the vent 412 is made of a suitable material that prevents the fill media from escaping from the tube 400.

For example, as PU foam is injected into the tube 400 near the fill end 410, the PU foam progresses towards the vented end 408, displacing any air that may have been in the tube 400 before filling. In addition, the CO₂ gas created during the mixing process may also be in the tube 400. The vent 412 allows the air and CO₂ gases to escape from the vented end 408 through the vent 412, but prevents the expanding PU foam from escaping the tube 400. In this manner, the tube 400 is filled with the PU foam with substantially no voids. FIG. 7 illustrates an exemplary cross-section of tube 400 filled with PU foam 702 and with substantially no voids.

Other embodiments may include other venting techniques, alone or in combination. For example, if the fill media needs to be de-gassed, such as, for example, PU foam, micro-sized holes can be added to the tube wall 402, such that the holes are small enough to let gas escape but not the fill media. Another option is to form tube walls 402 from fine woven cloth or non-porous plastic which is perforated to allow gas to escape but not the fill media. Any number of known venting techniques may be utilized and integrated into the tube 400.

In some embodiments, the vented end 408 and/or fill end 410 may be constructed using rigid materials. As shown in FIGS. 4-6, the fill end 410 is shown with an exemplary rigid end cap 414. The end cap 414 may be made from any suitable material with a desired stiffness. In one embodiment, the end cap 414 is substantially flat and more rigid than the tube wall 402 material. In some embodiments, the end cap 414 may be used to interface with a flat surface, including, for example, the ground, an anchor, another end cap 414, and/or other interfacing features. In one embodiment, as shown in FIGS. 4 and 6, the end cap 414 may include a feature 416, such as, for example, a recessed pocket, stub, etc. for receiving a pin or other mating device that may be used to interface with another feature and/or surface, including, for example, the ground, an anchor, a cable or rope, another end cap 414, other construction materials, or other interfacing features. As can be appreciated, any number of features may be integrated with, attached to, or associated with the end cap 414 for interfacing with other components in a modular manner.

In other embodiments, vents 412 and/or end caps 414 may be utilized on each end of the tube 400. For example, a vent 412 may be integrated into an end cap 414, including embodiments where the vent 412 is in addition to the other features of the end cap 414 discussed above.

Also shown in FIGS. 4-6, the tube 400 may include one or more attachment surfaces 420 for mating with complementary surfaces of a mating support sleeve, as discussed below, or any other features or components associated with a shelter. These attachment surfaces 420 may include any suitable fastening means, including, for example, hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc. In this embodiment, the attachment surfaces 420 are shown as hook-and-loop patches and strips. As can be appreciated, the attachment surfaces 420 may include any number, any type, and combinations thereof suitable for any particular application.

The various features of the tube 400, including, for example, the fill port 404, the plug 405, the sight window 406, the vent 412, the end cap 414, the attachment surfaces 420, etc. may be manufactured using any suitable materials and processes, and attached to the tube 400 using any suitable processes, including, for example, gluing, bonding, molding (including, e.g., insert-molding, co-molding, etc.), welding (including, e.g., RF-welding, ultrasonic welding, laser welding, etc.), staking (including, e.g., heat-staking), sewing, stitching, joining, press-fitting, interference-fitting, fastening using fasteners, etc., including the use of other processing materials, such as, for example, glues, fillers, accelerants, catalysts, primers, seals, fasteners, other agents, etc.

FIG. 8 illustrates a perspective view of an exemplary support sleeve 800 in a flat state. A support sleeve may be used to surround one or more fillable support tubes. A modular structural support, as discussed above, includes a support tube within a support sleeve. In this embodiment, support sleeve 800 is configured to accommodate up to two fillable support tubes (e.g., support tubes 400). Support sleeve 800 includes a sleeve wall 802 constructed of plastic, fabric, cloth, mesh, coated mesh, vinyl coated fabric (e.g., Bondcote® H13-645), thermoplastic, polyethylene, PVC, or any plastic or rubber similar to that used for inflatable rafts or thicker plastic such as that used for tarps, including materials associated with tube wall 402, or the like. The sleeve wall 802 may be of various thicknesses and can be flexible, rigid, or include portions with more or less rigidity than others. For example, in one embodiment, the sleeve wall 802 may include generally flexible plastic material along with rigid members (i.e., stiffeners) (not shown) extending lengthwise and imbedded or attached around the periphery of the sleeve 800.

Sleeve 800 may also include one or more exemplary fill port holes 804 and one or more exemplary sight window holes 806. The fill port holes 804 are designed as clearance holes that allow for any fill ports 404 associated with a mating fillable support tube 400 to pass through the sleeve wall 802 of the sleeve 800 as the sleeve 800 is secured around the support tube 400, as discussed below in more detail. In embodiments where the fill ports 404 are generally flush with the surface of the fillable tube 400, the fill port holes 804 provide clearance holes that allow for a media dispensing tool to engage with the fill ports 404 associated with a mating fillable support tube 400 after the sleeve 800 is secured around the support tube 400. In other embodiments, various other clearance holes may be included in the sleeve 800 based on features of the fillable tube 400, including for example, holes for deflation valves, drain plugs, and other components, such as, for example, wiring, tubing, piping, etc.

The sight window holes 806 are designed as clearance holes that allow for viewing any sight windows 406 associated with a mating fillable support tube 400 after the sleeve 800 is secured around the support tube 400, as discussed below in more detail. In other embodiments, the sleeve 800 may include detachable or hinged covers to cover the fill port holes 804 and/or sight window holes 806 as needed for protection, aesthetics, etc.

The locations of the fill port holes 804 and the sight window holes 806 are dictated by the features of the mating support tube 400. However, the features of various support tubes 400 may vary depending on the application, including for example, the dimensions of the tube 400, fill media, locations of fill ports 404, locations of sight windows 406, presence of other features, etc. In some embodiments, a multi-use or universal sleeve 800 may be configured with clearance holes, such as, for example, fill port holes 804 and sight window holes 806, accommodating a plurality of various support tube 400 configurations. In these embodiments, some clearance holes in the sleeve 800 not associated with features of the selected, mating support tube 400 will not be utilized.

Also shown in FIG. 8, the sleeve 800 may include one or more attachment surfaces 820 for mating with complementary surfaces of a mating fillable tube 400, such as, for example attachment surfaces 420. These attachment surfaces 820 may include any suitable fastening means, including, for example, hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc. In this embodiment, the attachment surfaces 820 are shown as hook-and-loop patches and strips. As can be appreciated, the attachment surfaces 820 may include any number, any type, and combinations thereof suitable for any particular application. In one embodiment utilizing hook-and-loop (e.g., Velcro®) materials, one attachment surface 420, 820 would include the hook feature and the other attachment surface 420, 820 would include the complementary loop feature.

Sleeve 800 may also include one or more paired attachment surfaces 830 for mating with each other after the sleeve 800 is wrapped around a mating support tube 400, as discussed in more detail below. These attachment surfaces 830 may also include any suitable fastening means, including, for example, hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc. In this embodiment, the attachment surfaces 830 are shown as hook-and-loop strips. As can be appreciated, the attachment surfaces 830 may include any number, any type, and combinations thereof suitable for any particular application. In one embodiment utilizing hook-and-loop (e.g., Velcro®) materials, one attachment surface 830 would include the hook feature and the other attachment surface 830 would include the complementary loop feature.

Sleeve 800 may also include one or more end straps 840 for securing the end (e.g., with or without a vent 412 and/or an end cap 414) of a mating support tube 400 within the sleeve 800 after the sleeve 800 is wrapped around the mating support tube 400. The straps 840 and sleeve 800 may also include one or more paired attachment surfaces 850 for mating with each other after the sleeve 800 is wrapped around the mating support tube 400, as discussed in more detail below. These attachment surfaces 850 may also include any suitable fastening means, including, for example, hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc. In this embodiment, the attachment surfaces 850 are shown as hook-and-loop strips. As can be appreciated, the attachment surfaces 850 may include any number, any type, and combinations thereof suitable for any particular application. In one embodiment utilizing hook-and-loop (e.g., Velcro®) materials, one attachment surface 850 would include the hook feature and the other attachment surface 850 would include the complementary loop feature.

The various features of the sleeve 800, including, for example, the attachment surfaces 820, 830, 850, (and 910 as discussed below), straps 840, etc. may be manufactured using any suitable materials and processes, and attached to the sleeve 800 using any suitable processes, including, for example, gluing, bonding, molding (including, e.g., insert-molding, co-molding, etc.), welding (including, e.g., RF-welding, ultrasonic welding, laser welding, etc.), staking (including, e.g., heat-staking), sewing, stitching, joining, press-fitting, interference-fitting, fastening using fasteners, etc., including the use of other processing materials, such as, for example, glues, fillers, accelerants, catalysts, primers, seals, fasteners, other agents, etc.

FIG. 9 illustrates a perspective view of an exemplary structural support 900 during assembly. In this embodiment, structural support 900 includes one support sleeve 800 and two fillable support tubes 400. In other embodiments, a structural support may include only one support tube or more than two support tubes. In this embodiment, support tubes 400 are shown in their filled state, however, in other embodiments, support tubes 400 may be inserted into the support sleeve 800 in an unfilled or partially filled state and filled after being surrounded by the support sleeve 800, utilizing the fill port holes 804 and sight window holes 806 in the support sleeve 800.

In this embodiment, the two support tubes 400 are placed on top of the support sleeve 800 with their end caps 414 (not visible) abutting each other in the middle of the support sleeve 800. Support tubes 400 are oriented such that the features of the support tubes 400 align with the corresponding features of the support sleeve 800. In particular, the attachment surfaces 420 of the support tubes 400 are aligned with and attached to the attachment surfaces 820 of the support sleeve 800, the fill ports 404 of the support tubes 400 are aligned with the fill port holes 804 of the support sleeve 800, and the sight windows 406 of the support tubes 400 are aligned with the sight window holes 806 of the support sleeve 800.

In addition, the paired attachment surfaces 830 for mating with each other are aligned and attached to each other after wrapping the support sleeve 800 around the mating support tubes 400. After attachment surfaces 830 of the support sleeve 800 are mated together, the end straps 840 of the support sleeve 800 are wrapped around the end of the support tubes 400 such that the paired attachment surfaces 850 for mating with each other are aligned and attached to each other. In various other embodiments, more or less, including different attachment surfaces may be utilized to sufficiently secure the support tubes in the support sleeve. If the support tubes are secured in the support sleeve unfilled or partially filled, the support tubes may be filled after being secured in the support sleeve.

Also shown in FIG. 9, the sleeve 800 may include one or more attachment surfaces 910 for mating with complementary surfaces, including, for example, straps, attachment surfaces, etc. of a mating feature or component associated with a shelter. These attachment surfaces 910 may include any suitable fastening means, including, for example, hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc. The attachment surface 910 is a feature that increases the modularity of the structural support 900 by providing the structural support 900 with a universal attachment means that may be utilized in various manners, including in applications and as part of assemblies unforeseen and/or unanticipated at the time of preparing the structural support 900. As can be appreciated, the attachment surfaces 910 may include any number, any type, and combinations thereof suitable for any particular application. In other embodiments, instead of a solid sleeve, a sleeve may be comprised of end sections and one or more middle sections connected with strips of material or ropes, cables, etc. to capture the ends of the tubes and where a plurality of tubes meet to prevent them from moving. In yet other embodiments, the sleeve may be perforated and/or include various open sections, so long as the tubes within the sleeve are stabilized together.

FIG. 10 illustrates a perspective view of an exemplary structural support 1000 after assembly. In this embodiment, structural support 1000 includes one support sleeve 800 and two fillable support tubes 400. Structural support 1000 is the completed version of structural support 900, shown during assembly in FIG. 9. Support sleeves can allow more than one support tubes to be mated at unions, joints, intersections, etc. without creating a “weak spot” in the structure. For example, as shown in FIG. 10, two support tubes 400 can be fixed into one structural support 1000 that is longer than the individual tubes 400, yet still exhibits the same properties, including, for example, strength, rigidity, etc. I.e., the sleeve 800 allows the two tubes 400 to perform the same as one longer tube. In this manner, the modularity and portability of structural supports for shelters is not limited by strength, and vice versa.

FIG. 11 illustrates a perspective view of an exemplary structural support 1100 during assembly. In this embodiment, structural support 1100 includes one support sleeve 1110 and one fillable support tube 1120. Generally, structural support 1100 is a one-tube version of the two-tube structural support 900 shown in FIG. 9. In this embodiment, support tube 1120 is shown in its filled state, however, in other embodiments, support tube 1120 may be inserted into support sleeve 1110 in an unfilled state and filled after being surrounded by the support sleeve 1110, utilizing the fill port hole 1145 and sight window hole 1155 in the support sleeve 1110.

In this embodiment, the support tube 1120 is placed on top of the support sleeve 1110 with an end cap 1114 of the support tube 1120 at the end of the support sleeve 1110. Support tube 1120 is oriented such that the features of the support tube 1120 align with the corresponding features of the support sleeve 1110. In particular, attachment surfaces 1130 of the support tube 1120 are aligned with and attached to attachment surfaces 1135 of the support sleeve 1110, a fill port 1140 of the support tube 1120 is aligned with a fill port hole 1145 of the support sleeve 1110, and a sight window 1150 of the support tube 1120 is aligned with a sight window hole 1155 of the support sleeve 1110.

In addition, paired attachment surfaces 1160 for mating with each other are aligned and attached to each other after wrapping the support sleeve 1110 around the mating support tube 1120. After attachment surfaces 1160 of the support sleeve 1110 are mated together, end straps 1170 of the support sleeve 1110 are wrapped around the ends of the support tube 1120 such that paired attachment surfaces 1175 for mating with each other are aligned and attached to each other. In various other embodiments, more or less, including different attachment surfaces may be utilized to sufficiently secure the support tube in the support sleeve. If the support tube is secured in the support sleeve unfilled or partially filled, the support tube may be filled after being secured in the support sleeve.

Also shown in FIG. 11, the sleeve 1110 may include one or more attachment surfaces 1180 for mating with complementary surfaces, including, for example, straps, of a mating feature or component associated with a shelter. These attachment surfaces 1180 may include any suitable fastening means, including, for example, hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc. The attachment surface 1180 is a feature that increases the modularity of the structural support 1100 by providing the structural support 1100 with a universal attachment means that may be utilized in various manners, including in applications and as part of assemblies unforeseen and/or unanticipated at the time of preparing the structural support 1100. As can be appreciated, the attachment surfaces 1180 may include any number, any type, and combinations thereof suitable for any particular application.

FIG. 12 illustrates a perspective view of an exemplary structural support 1200 after assembly. In this embodiment, structural support 1200 includes one support sleeve 1110 and one fillable support tube 1120. Structural support 1200 is the completed version of structural support 1100, shown during assembly in FIG. 11. Generally, structural support 1200 is a one-tube version of the two-tube structural support 1000 shown in FIG. 10. In some embodiments, three or more tubes may be used.

FIG. 13 illustrates a perspective view of another exemplary fillable support tube 1300 in an unfilled state. In this embodiment, tube 1300 includes a tube wall 1302 constructed of plastic, fabric, cloth, mesh, coated mesh, vinyl coated fabric (e.g., Bondcote® H13-645), thermoplastic, polyethylene, PVC, or any plastic or rubber similar to that used for inflatable rafts or thicker plastic such as that used for tarps. The tube wall 1302 may be of various thicknesses and can be flexible, rigid, or include portions with more or less rigidity than others. For example, in one embodiment, the tube wall 1302 may include generally flexible plastic material along with rigid members (i.e., stiffeners) extending lengthwise and imbedded or attached around the periphery of the tube 1300.

Tube 1300 may also include an exemplary fill port 1304. The fill port 1304 is where the fill media is injected into the tube 1300 using, for example, a media dispensing tool. Some embodiments may include tubes 1300 that have multiple fill ports 1304. The fill port 1304 may be made from any suitable material and be of any design suitable for the fill media and/or the dispensing tool. The fill port 1304 may include an open/close mechanism, such as, for example a plug 1305. In other embodiments, the fill port 1304 may include one or more valves, including, for example, check valves to prevent media from escaping the tube 1300. By filling the tube 1300 with media, the tube (and its associated structural support, as discussed below) may have additional rigidity and stiffness, additional structural strength, maintain its shape better, and/or act as an insulator. In some embodiments, different tubes 1300 may be filled with different media or no media at all.

The tube 1300 may be filled with various media, including, for example, water, gas, foam, etc. In one embodiment, as shown in FIG. 13, the tube 1300 is designed to be filled with a gas, such as, for example, air, using, for example, pressurized air provided, for example, by a cylinder of pressurized air, an inflator type air pump, etc. A variety of sources of pressurized gas may be integrated with one or more modular assemblies of a shelter. Various other gases, including, for example, inert, non-flammable, and/or non-volatile gases, etc. may also be used.

The location of the fill port 1304 may be determined based on the particular application and fill media. For example, in this embodiment, the location of the fill port 1304 may be based primarily on convenience for manufacture or filling since the fill gas will naturally distribute throughout the tube 1304 to equalize pressure. In other embodiments, the tube 1304 may also include relief, bleed, and/or overpressure valves to prevent overfilling and/or rupture of the tube 1304. Various pressures suitable for the application and tube 1300 strength may be used. In one embodiment, the tube 1300 may be filled to an internal maximum pressure of 15 psi. In other embodiments, the tube 1300 may be filled to an internal maximum pressure of 5 psi or 3 psi.

The tube 1300 may be manufactured using any suitable process, including one-piece and multi-piece designs. For example, the tube 1300 may be formed, for example, using a molding or blow-molding process, in a one-piece manner (e.g., like a balloon), wherein, for example, the fill port 1304 may be placed at the molding feed or vent. In other embodiments, the tube 1304 may be formed, for example, using a radio-frequency (RF) welding, heat-staking, gluing, bonding, and/or stitching/sealing process, from multiple pieces, wherein a lip seal is formed where the pieces are overlapped and joined. An exemplary lip seal is shown in FIG. 13 as edge 1310, where the tube wall 1302 is formed from two pieces using an RF welding process along edge 1310 to create the sealed tube 1300.

With continued reference to FIG. 13 and with further reference to FIG. 14, which shows the exemplary fillable support tube 1300 in a filled state, the tube 1300 may include one or more attachment surfaces 1320 for mating with complementary surfaces of a mating support sleeve, as discussed below, or any other features or components associated with a shelter. These attachment surfaces 1320 may include any suitable fastening means, including, for example, hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc. In this embodiment, the attachment surfaces 1320 are shown as hook-and-loop patches and strips. As can be appreciated, the attachment surfaces 1320 may include any number, any type, and combinations thereof suitable for any particular application.

FIG. 15 illustrates a perspective view of another exemplary fillable support tube 1500 in a filled state. In this embodiment, tube 1500 is similar to the exemplary fillable support tube 1300 shown in FIGS. 13-14 in most respects, except that tube 1500 is substantially longer than tube 1300. A tube wall 1502, a fill port 1504, a plug 1505, an edge 1510, and attachment surfaces 1520 may have similar materials, properties, characteristics, associated processes, etc. as the tube wall 1302, the fill port 1304, the plug 1305, the edge 1310, and attachment surfaces 1320 of tube 1300, respectively, albeit with a longer length tube 1500.

It should be appreciated that although certain tubes (e.g., tubes 400, 1120, 1300, 1500 discussed above) are shown with exemplary lengths, the lengths illustrated herein are for exemplary purposes only. Tube widths, diameters, and cross-sections are also illustrated herein are for exemplary purposes only. Although shown generally with a circular cross-section, tube cross-sections may have any shape suitable for a particular application, including, for example, oval, elliptical, square, rectangular, etc. Tube size, configuration, cross-section, etc., may be based on a variety of factors, including, for example, the intended application, cost, modularity, shipping ease, durability, strength, etc.

For example, in one embodiment, tubes 400, 1120, 1300, may be approximately 4 feet long and have a diameter of approximately 4.5 inches, and tube 1500 may be approximately 8 feet long and have a diameter of approximately 4.5 inches. Other embodiments include tubes with larger and smaller lengths, widths, diameters, etc. In some embodiments, modularity may allow one tube 1500 to be interchangeable with two tubes 1300 with interfacing ends. In other embodiments, foam-filed tubes 400, 1120 may be interchangeable and/or combinable with gas-filled tubes 1300, 1500, as well as interchangeability with various other fill media. It should be appreciated that various sizes and configurations of tubes and associated sleeves may be used to create various structural supports for any number of applications. In some ways, the modularity of the structural supports is akin to the various sizes of lumber for use as studs, posts, columns, joists, headers, rafters, trusses, etc. (e.g., various lengths of 2×4s, 4×4s, 2×6s, 2×8s, 2×10s, etc.)

The various features of the tubes 1300, 1500, including, for example, the fill ports 1304, 1504 the plugs 1305, 1505 (the end cap 1714 as discussed below), the attachment surfaces 1320, 1520, etc. may be manufactured using any suitable materials and processes, and attached to the tubes 1300, 1500 using any suitable processes, including, for example, gluing, bonding, molding (including, e.g., insert-molding, co-molding, etc.), welding (including, e.g., RF-welding, ultrasonic welding, laser welding, etc.), staking (including, e.g., heat-staking), sewing, stitching, joining, press-fitting, interference-fitting, fastening using fasteners, etc., including the use of other processing materials, such as, for example, glues, fillers, accelerants, catalysts, primers, seals, fasteners, other agents, etc.

FIG. 16 illustrates a perspective view of an exemplary structural support 1600 during assembly. In this embodiment, structural support 1600 includes one support sleeve 1610 and one fillable support tube 1620 (which may be, e.g., air-filled support tube 1500). In this embodiment, support tube 1620 is shown in its filled state, however, in other embodiments, support tube 1620 may be inserted into support sleeve 1610 in an unfilled or partially filled state and filled after being surrounded by the support sleeve 1610, utilizing the fill port hole 1645 in the support sleeve 1610.

In this embodiment, the support tube 1620 is placed on top of the support sleeve 1610. Support tube 1620 is oriented such that the features of the support tube 1620 align with the corresponding features of the support sleeve 1610. In particular, attachment surfaces 1630 of the support tube 1620 are aligned with and attached to attachment surfaces 1635 of the support sleeve 1610 and a fill port 1640 of the support tube 1620 is aligned with a fill port hole 1645 of the support sleeve 1610.

In addition, paired attachment surfaces 1660 for mating with each other are aligned and attached to each other after wrapping the support sleeve 1610 around the mating support tube 1620. After attachment surfaces 1660 of the support sleeve 1610 are mated together, end straps 1670 of the support sleeve 1610 are wrapped around the ends of the support tube 1620 such that the paired attachment surfaces 1675 for mating with each other are aligned and attached to each other. In various other embodiments, more or less, including different attachment surfaces may be utilized to sufficiently secure the support tube in the support sleeve. If the support tube is secured in the support sleeve unfilled or partially filled, the support tube may be filled after being secured in the support sleeve.

Also shown in FIG. 16, the sleeve 1610 may include one or more attachment surfaces 1680 for mating with complementary surfaces, including, for example, straps, of a mating feature or component associated with a shelter. These attachment surfaces 1680 may include any suitable fastening means, including, for example, hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc. The attachment surface 1680 is a feature that increases the modularity of the structural support 1600 by providing the structural support 1600 with a universal attachment means that may be utilized in various manners, including in applications and as part of assemblies unforeseen and/or unanticipated at the time of preparing the structural support 1600. As can be appreciated, the attachment surfaces 1680 may include any number, any type, and combinations thereof suitable for any particular application.

The various features of the sleeve 1610, including, for example, the attachment surfaces 1635, 1660, 1675, and 1680, straps 1670, etc. may be manufactured using any suitable materials and processes, and attached to the sleeve 1610 using any suitable processes, including, for example, gluing, bonding, molding (including, e.g., insert-molding, co-molding, etc.), welding (including, e.g., RF-welding, ultrasonic welding, laser welding, etc.), staking (including, e.g., heat-staking), sewing, stitching, joining, press-fitting, interference-fitting, fastening using fasteners, etc., including the use of other processing materials, such as, for example, glues, fillers, accelerants, catalysts, primers, seals, fasteners, other agents, etc.

FIG. 17 illustrates a perspective view of an exemplary structural support 1700 after assembly. In this embodiment, structural support 1700 includes one support sleeve 1710 and one fillable support tube 1720 (e.g., an air-filled support tube). Support tube 1720 is oriented such that the features of the support tube 1720 align with the corresponding features of the support sleeve 1710. In particular, attachment surfaces of the support tube are aligned with and attached to attachment surfaces of the support sleeve 1710 and a fill port 1740 of the support tube 1720 is aligned with a fill port hole 1745 of the support sleeve 1710. In addition, after attachment surfaces of the support sleeve 1710 are mated together, end straps 1770 of the support sleeve 1710 are wrapped around the ends of the support tube 1720 such that paired attachment surfaces for mating with each other are aligned and attached to each other. Also shown in FIG. 17, the sleeve 1710 may include one or more attachment surfaces 1780 for mating with complementary surfaces, including, for example, straps, of a mating feature or component associated with a shelter.

FIG. 17 also shows air-filled tube 1720 with an end cap that may be utilized on one or both ends of the tube 1720. In some embodiments, as shown in FIG. 17, the tube 1720 is shown with an exemplary rigid end cap 1714. The end cap 1714 may be made from any suitable material with a desired stiffness. In one embodiment, the end cap 1714 is substantially flat and more rigid than the tube 1702 wall material. In some embodiments, the end cap 1714 may be used to interface with a flat surface, including, for example, the ground, an anchor, another end cap 1714, or other interfacing features. In one embodiment, the end cap 1714 may include a feature (not shown), such as, for example, a recessed pocket, stub, etc. for receiving a pin or other mating device that may be used to interface with another feature and/or surface, including, for example, the ground, an anchor, a cable or rope, another end cap 1714, other construction materials, or other interfacing features. As can be appreciated, any number of features may be integrated with, attached to, or associated with the end cap 1714 for interfacing with other components in a modular manner.

As mentioned above, structural supports (such as, e.g., structural supports 1000, 1200, 1600, 1700) typically include a support sleeve (such as, e.g., support sleeves 800, 1110, 1610, 1710) surrounding one or more fillable support tubes (such as, e.g., fillable support tubes 400, 1120, 1300, 1500, 1620, 1720). Structural supports (such as, e.g., structural supports 304, 306, 310 shown in FIG. 3) may be utilized to provide the framework of the various assemblies and columns (such as, e.g., 102, 104, 106, 108, 202, 204, 206, 302, 306, 308 shown in FIGS. 1-3), which may be used to construct a shelter (such as, e.g., shelters 100, 200, 300 shown in FIGS. 1-3). The combination of support sleeves and fillable support tubes provides structural supports that can provide additional strength, insulation, rigidity, etc. for a shelter. (See testing data below.)

The various assemblies (such as, e.g., 102, 104, 106, 202, 204, 206, 302, 308 shown in FIGS. 1-3) may be constructed using individual structural supports (such as, e.g., structural supports 1000, 1200, 1600, 1700) or may be constructed using modular sleeve assemblies.

FIG. 18 illustrates a perspective view of an exemplary column/header assembly 1800 in an unfilled state. In this embodiment, an exemplary sleeve assembly 1810 is shown with two vertical support member sleeves 1820, two horizontal header support member sleeves 1822, and one vertical header support member sleeve 1824. In this embodiment, the sleeve assembly 1810 is pre-configured to be used in a modular manner with other preconfigured assemblies and columns (such as, e.g., 102, 104, 106, 108, 202, 204, 206, 302, 306, 308) or individual structural supports (such as, e.g., 1000, 1200, 1600, 1700).

The two vertical support member sleeves 1820, two horizontal header support members 1822, and one vertical header support member 1824 of sleeve assembly 1810 are joined using any suitable joining means, including, for example, gluing, bonding, molding, welding (including, e.g., RF-welding, ultrasonic welding, laser welding, etc.), staking (including, e.g., heat-staking), sewing, stitching, fastening using fasteners (including, e.g., hook-and-loop (e.g., Velcro®), clips, hooks, buttons, adhesive, tape, etc.), including the use of other processing materials, such as, for example, glues, fillers, accelerants, catalysts, primers, seals, fasteners, other agents, etc. In this embodiment, sleeve assembly 1810 includes joining straps 1830 for joining the two vertical support member sleeves 1820, two horizontal header support member sleeves 1822, and one vertical header support member sleeve 1824 together.

FIG. 18 also shows various straps 1840 for closing the sleeves 1820, 1822, 1824 of the sleeve assembly 1810 around various fillable tubes (such as, e.g., 400, 1120, 1300, 1500, 1620, 1720) and/or attaching to other individual structural supports (such as, e.g., 1000, 1200, 1600, 1700). FIG. 18 also shows various fill port holes/sight window holes 1850. Some or all of these holes may be utilized, depending on the support tubes selected for use with the sleeve assembly 1810. Sleeve assembly 1810 may be configured to accept a variety of types and/or sizes of support tubes. For example, air tubes and foam tubes may both be used, exclusively or in combinations, depending on the application's requirements. In another example, support member sleeves 1820, 1822 may surround one long support tube or may surround two or more shorter support tubes arranged end-to-end, for example, with interfacing rigid end caps.

FIG. 19 illustrates a perspective view of an exemplary column/header assembly 1900 in a filled state. In this embodiment, the exemplary sleeve assembly 1810 is shown where the two vertical support member sleeves 1820, the two horizontal header support member sleeves 1822, and the vertical header support member sleeve 1824, surrounding filled support tubes. The support tubes can be filled before and/or after being placed in the sleeve assembly 1810. For example, air-filled tubes may first be partially inflated to create their rough shape, then inserted into the sleeve assembly 1810, and then inflated to the desired air pressure. This may be a preferred sequence in embodiments where the filled tubes create a very rigid and tight fit within the sleeve or sleeve assembly.

An advantage of sleeve assemblies, including, for example, sleeve assembly 1810, is that the support tubes within the sleeve assembly can form around a mating support tube as the tubes are filled, establishing a “saddle” type connection. For example, if the tubes in the vertical support member sleeves 1820 are formed first, the ends of the tubes in the horizontal header support member sleeves 1822 may form around the sides of the tubes in the vertical support member sleeves 1820 as the tubes in the horizontal header support member sleeves 1822 are being filled. If the tubes in the horizontal header support member sleeves 1822 are formed first, the sides of the tubes in the vertical support member sleeves 1820 may form around the ends of the tubes in the horizontal header support member sleeves 1822 as the tubes in the vertical support member sleeves 1820 are being filled. If they are filled at the same time, a combination of the above interactions can occur. In any event, these interactions create a mechanical locking feature at these intersections, further strengthening the assembly and shelter. This interaction may also be achieved with other support tubes filled in close proximity to each other.

In one embodiment, column/header assembly 1900 may be used as an inside or outside (e.g., with sheeting) wall assembly to interface with and/or support a roof assembly, such as, for example, roof assemblies 102, 202, 302. In various other embodiments, individual structural supports (such as, e.g., 1000, 1200, 1600, 1700) may be added to a modular assembly, such as, for example, column/header assembly 1900, to create more customized configurations, including, for example, doorways, window frames, partitions, etc. (such as, e.g., assemblies 102, 104, 106, 202, 204, 206, 302, 308 shown in FIGS. 1-3). These additional structural supports may be attached in various manners, including, for example, utilizing straps 1840, attachment surfaces 910, 1180, 1680, 1780, stand-alone straps, etc. In should be appreciated that any of the attaching and joining processes described above may be utilized.

FIG. 20 illustrates a top view of an exemplary set of support sleeves 2000 in a flat state. The set of sleeves 2000 may be used as part of an assembly, such as, for example, a wall assembly. The set of sleeves 2000 includes six support sleeves 2010 for horizontal support members and three support sleeves 2020 for vertical support members. FIG. 20 also includes sheeting 2030. The support sleeves 2010, 2020 are secured to the sheeting 2030. The support sleeves 2010, 2020 and sheeting 2030 may be any type and configuration as described above, including, for example, attachment surfaces and straps.

FIG. 21 illustrates a top view of an exemplary set of fillable support tubes 2100 on top of the set of support sleeves 2000. The set of tubes 2100 may be used as part of an assembly, such as, for example, a wall assembly. The set of tubes 2100 includes six support tubes 2110 for horizontal support members and six support tubes 2120 in pairs for vertical support members with interfacing rigid end caps 2125. The support tubes 2110, 2120 may be any type and configuration as described above.

FIG. 21 also includes an exemplary media delivery system, including a media supply line 2140, a media distribution block 2150, and media distribution lines 2160. In one embodiment, where the fill media is a gas, such as, for example, air, the media supply line 2140, acting as a common fill port, may be a pressurized air supply or include a pump, such as an inflator, the media distribution block 2150 may be a gas manifold, and the media distribution lines 2160 may act as a gas pathway, including tubing, piping, etc. Each of the supply lines 2160 can deliver media (e.g., air) to each of the support tubes 2110, 2120, including via support tube 2110, 2120 fill ports. Other components common to gas delivery systems may also be include, for example, a controller (e.g., for solenoid valve actuation), various relief valves/discs, purge/deflation valves and/or ports, pumps, dryers, filters, pressure sensors, pressure gauges, orifices, etc. In some embodiments, an inflator (including, e.g., solar powered) may be used to automatically inflate and/or periodically “top-off” the support tubes 2110, 2120, including embodiments with tube pressure feedback.

As shown in FIG. 21, the media distribution lines 2160 may be routed to each of the support tubes 2110, 2120 within the set of support sleeves 2000 (sleeves 2010, 2020) for concealment, protection, etc. In some embodiments, all or certain parts of the media delivery system may be included in a modular assembly. In one embodiment, the entire media delivery system is included in a modular assembly, such that a user need only connect the media supply line (e.g., a pressurized air line) to the supply line 2140 and optional electronic controls (not shown) to provide quick and easy filling of the entire assembly, as well as for ongoing monitoring and control, including, for example, for maintenance, deflation, etc. In this manner, individual tubes, structural supports, and/or entire assemblies can be isolated, deflated, repaired, removed, replaced, etc.

FIG. 22 is a block diagram of an exemplary media delivery system 2200, including a media inlet 2210, a valve block/manifold 2220, media distribution lines 2230, connections 2235, fillable support tubes 2240, and valves 2250. The exemplary connections 2235 may be any suitable connection for the media distribution lines 2230, including, for example, swivel disconnects. Exemplary valves 2250 may include a fill check valve device 2252, a check spring 2254, a screw-in deflation member 2256, along with other components necessary for proper sealing, movement, regulation, control, routing, etc. In an air-tube embodiment, air may be provided to the inlet 2210 at the desired pressure, which will be sufficient to overcome the spring force exerted on the check valve device 2252 by the check spring 2254 until the pressure in the air tubes 2240 (and air lines 2230) reaches a sufficient pressure to combine with the check spring 2254 to close the valve 2250 at the check valve device 2252. Each air tube 2240 may also be individually deflated by rotating the tube's corresponding threaded deflation member 2256 outward away from its sealing seat to allow the air path around the seat and check valve device 2252 to open, thus allowing the pressurized air in the tube 2240 to escape. In this manner, as mentioned above, individual tubes can be inflated, isolated, deflated, repaired, removed, replaced, re-inflated, etc.

FIG. 23 illustrates a top view of another exemplary set of fillable support tubes 2300 on top of the set of support sleeves 2000. The set of tubes 2300 may be used as part of an assembly, such as, for example, a wall assembly. The set of tubes 2300 includes six support tubes 2310 for horizontal support members and six support tubes 2320 in pairs for vertical support members with interfacing rigid end caps. The support tubes 2310, 2320 may be any type and configuration as described above.

FIG. 23 also includes an exemplary media delivery system, including a media supply line 2340, an optional media control device 2350, and media distribution system 2360. In one embodiment, where the fill media is a gas, such as, for example, air, the media supply line 2340 may be a pressurized air supply or include a pump, such as an inflator, the media control block 2350 may be any type of control device (including, e.g., a system manifold, regulator, sensor, and/or combinations thereof), and the media distribution system 2360 may act as a gas pathway that includes gas distribution system components (including, e.g., tubing, piping, unions, junctions, couplings, splitters, valves, etc.) for distributing the gas to each of the support tubes 2310, 2320, including via support tube 2310, 2320 fill ports.

In this embodiment, a check valve 2370 is associated with each of the support tubes 2310, 2320. In this manner, the set of tubes 2300 may be supplied with air via one air supply line 2340 acting as a common fill port, yet each of the support tubes 2310, 2320 is isolated from the other support tubes 2310, 2320, such that a loss of pressure in one or more of the support tubes 2310, 2320 will not cause a pressure loss in the remaining support tubes 2310, 2320. As mentioned above, other components common to gas delivery systems may also be included.

As shown in FIG. 23, the media distribution system 2360 may be contained within the set of support sleeves 2300 (sleeves 2310, 2320) for concealment, protection, etc. In this manner, individual tubes, structural supports, and/or entire assemblies can be isolated, deflated, repaired, removed, replaced, etc.

Returning now to the modularity of the system, FIG. 24 illustrates a side view of an exemplary hall assembly 2400 configured with a heating, ventilation, and/or air conditioning (HVAC) routing hole 2410. The hall assembly 2400 may include sheeting 2420, a window opening 2430, seams/reinforcements 2450, a roll-up man door 2460 (including, for example, with a closing mechanism 2465, such as, e.g., one or more zippers, hook-and-loop attachment surfaces, etc.), a roof portion, and/or other features associated with the modular assemblies mentioned above. The hall assembly 2400 may be connected between and/or supported by other assemblies, components, and/or supports, including, for example, header assemblies, wall assemblies, columns, etc.

With further reference to FIGS. 25 and 26, an exemplary HVAC plenum 2600 may be installed in the hall assembly 2400. FIG. 25 illustrates a side view of the hall assembly 2400 with a plenum inlet 2610 extending through the hall assembly 2400 HVAC routing hole 2410. In one embodiment, the plenum inlet 2610 may be attached to the hall assembly with a strap/buckle 2510 installed over a flange 2520.

FIG. 26 illustrates a perspective view of an exemplary HVAC plenum 2600, including the plenum inlet 2610, a plenum riser 2620, a plenum duct 2630, distribution ducts 2640, outlets 2650, and a plenum end 2660. The plenum may be constructed using any suitable material, such as those mentioned above, including flexible and/or rigid materials. In one embodiment, the plenum 2600 is constructed using flexible sheeting material and expands into the shape shown in FIG. 26 as positive pressure is directed through the plenum 2600.

The plenum end 2660 may be configured with an end cap or may be connected to additional duct work as part of a larger HVAC system, including, for example, connecting to ductwork in neighboring hall assemblies (that may serve as main runs). The outlets 2650 in the distribution ducts 2640 may be left open, configured with an end cap, and/or may be connected to additional duct work as part of a larger HVAC system to feed other areas connected to the hall assembly 2400. For example, with additional reference to FIG. 1, a hall assembly 106 may be configured with an HVAC plenum 2600 (e.g., hall assembly 2400) to support HVAC in the entire shelter 100 by routing ductwork from one hall assembly 106 to another hall assembly 106 and by routing ductwork from distribution ducts 2640 into each room or area abutting the hall assembly 106 (i.e., the rooms and/or areas formed by the roof assemblies 102 and wall assemblies 104), for example, through the header portions of the roof assemblies 102.

It should be appreciated that plenum 2600 may be configured in various manners and with a variety of pathways to support a variety of HVAC needs and applications.

Test Data/Results

Four exemplary support tubes were tested: one section of foam without a tube wall and three sections with tube walls with foam (from three different sections of the support tube). In particular: 1) sight window section of foam-filled tube; 2) center section of foam-filled tube; 3) fill end section of foam-filled tube; and 4) foam without tube wall. The tube walls were constructed using a vinyl coated fabric (Bondcote® H13-645) and the foam was PU foam.

Two Component Low Pressure Polyurethane Close Cell Foam Notes: Test Sample: 4.5″ Diameter, 12″ Long Foam Tube Volumn: 15.896 in2 = 0.1104 ft3 Weight 0.2775 lb no fabric Tube Diameter = 4.5″ (Area: 15.896 in2 = 0.110 ft2) Free Density: 1.75 lb/ft3 Contained Density: 2.514 lb/ft3

Column Number 1 Test (Sight Window Section) 4.5″ Diameter, 12″ Long Foam Tube With Fabric Tube Wall Test Down Up Pressure Load Deflection Deflection Time (PSIG) (lbf) (Inches) (Inches) (Min.) N/A N/A N/A 0 0.0 0 0.004 1 10 49.1 N/A No Wait 20 98.2 N/A 30 147.3 0.015 40 196.3 0.03 50 245.4 0.057 60 294.5 0.085 70 343.6 0.127 80 392.7 0.168 90 441.8 0.231 100 490.9 0.287 0.287 First Test Cycle N/A

Column Number 2 Test (Center Section) 4.5″ Diameter, 12″ Long Foam Tube With Fabric Tube Wall Test Down Up Pressure Load Deflection Deflection Time (PSIG) (lbf) (Inches) (Inches) (Min.) N/A N/A N/A 0 0.0 0 0.003 1 10 49.1 0.014 0.045 1 20 98.2 0.029 0.073 1 30 147.3 0.048 0.106 1 40 196.3 0.071 0.132 1 50 245.4 0.095 0.157 1 60 294.5 0.124 0.181 1 70 343.6 0.152 0.211 1 80 392.7 0.183 0.228 1 90 441.8 0.213 0.245 1 100 490.9 0.249 0.249 1 First Test Cycle N/A

Column Number 3 Test (Fill End Section) 4.5″ Diameter, 12″ Long Foam Tube With Fabric Tube Wall Test Down Up Down Up Pressure Load Deflection Deflection Deflection Deflection Time (PSIG) (lbf) (Inches) (Inches) Time (Min.) (Inches) (Inches) (Min.) 0 0.0 0 0.002 1 0 0.007 1 10 49.1 0.008 0.043 1 0.012 0.045 1 20 98.2 0.02 0.077 1 0.03 0.078 1 30 147.3 0.039 0.113 1 0.051 0.108 1 40 196.3 0.067 0.151 1 0.078 0.137 1 50 245.4 0.09 0.182 1 0.104 0.169 1 60 294.5 0.125 0.209 1 0.135 0.192 1 70 343.6 0.152 0.24 1 0.164 0.222 1 80 392.7 0.183 0.262 1 0.2 0.244 1 90 441.8 0.22 0.262 1 0.242 0.266 1 100 490.9 0.262 0.262 1 0.272 0.272 1 First Test Cycle Second Test Cycle

Column Number 4 Test 4.5″ Diameter, 12″ Long Foam Tube With No Fabric Tube Wall Test Down Up Pressure Load Deflection Time Deflection Time (PSIG) (lbf) (Inches) (Min.) (Inches) (Min.) 0 0.0 0 0 0.279 2 0.326 1 10 49.1 0.024 1 0.596 1 20 98.2 0.069 1 0.793 1 30 147.3 0.108 1 0.967 1 40 196.3 0.149 1 1.102 1 50 245.4 0.194 1 1.182 1 60 294.5 0.245 1 1.179 1 70 343.6 0.315 1 1.179 1 80 392.7 0.403 1 1.174 1 90 441.8 0.541 1 1.165 1 Slight cracking sounds (Little to no cracking sounds.) 100 490.9 0.947 1 1.073 1 Tube failing; cracking and bowing 100 490.9 1.073 2 1.073 1 Tube failing; cracking and bowing

FIG. 27 is a line graph comparing the test results from these four sections. The test results demonstrate the strength provided by the support tube wall (tests 1-3) when compared to the foam without the tube wall (test 4). In addition, the test results show the consistency of the support tube strength throughout the different sections of the foam-filled tube (tests 1-3).

As mentioned above, support sleeves allow the properties of support tubes to be translated into longer length structural supports and complicated assembly configurations. I.e., sleeves and sleeve assemblies allow multiple support tubes to act as if they were one larger support tube.

While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. For example, component types, geometries, shapes, and dimensions can be modified without changing the overall role or function of the components. Therefore, the inventive concept, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept. 

What is claimed:
 1. An inflatable shelter, comprising: a plurality of columns; a plurality of wall assemblies; at least one roof assembly supported by columns; wherein the columns, the wall assemblies, and the at least one roof assembly comprise at least one structural support, and wherein the at least one structural support comprises: a support sleeve; and at least one fillable support tube inserted within the support sleeve.
 2. The inflatable shelter of claim 1, wherein the inflatable shelter is expandable using at least one of another column, another wall assembly, and another roof assembly.
 3. The inflatable shelter of claim 1, wherein the inflatable shelter is capable of disassembly.
 4. The inflatable shelter of claim 1, wherein at least one of the plurality of columns, the plurality of wall assemblies, and the at least one roof assembly is reusable in a second inflatable shelter.
 5. The inflatable shelter of claim 1, wherein the at least one fillable support tube is deflatable and replaceable.
 6. A structural support for an inflatable shelter assembly, comprising: a support sleeve; and at least one fillable support tube inserted within the support sleeve.
 7. The structural support of claim 6, wherein the support sleeve extends along substantially a length of the at least one fillable support tube.
 8. The structural support of claim 6, wherein the at least one fillable support tube is filled with an expandable material.
 9. The structural support of claim 8, wherein the expandable material is a foam.
 10. The structural support of claim 8, wherein the at least one fillable support tube comprises a tube sight window for allowing viewing of the progression of the expandable material during filling of the at least one fillable support tube.
 11. The structural support of claim 10, wherein the support sleeve comprises a sleeve sight window for allowing viewing of the progression of the expandable material during filling of the at least one fillable support tube, wherein the tube sight window and the sleeve sight window are aligned.
 12. The structural support of claim 8, wherein the at least one fillable support tube comprises a vent for allowing gas to escape from within the at least one fillable support tube as the at least one fillable support tube is filled with the expandable material.
 13. The structural support of claim 8, wherein the at least one fillable support tube comprises at least one end cap.
 14. The structural support of claim 8, wherein the at least one fillable support tube has a deflection of between about 0.05 and 0.25 inches per linear foot at 70 psig after the at least one fillable support tube is filled with the expandable material and the expandable material is cured.
 15. The structural support of claim 8, wherein the structural support comprises a plurality of fillable support tubes inserted within the support sleeve.
 16. The structural support of claim 15, wherein at least two fillable support tubes have an end cap and wherein the at least two fillable support tubes are arranged so that the end caps meet at an interface.
 17. The structural support of claim 6, wherein the at least one fillable support tube is filled with a gas.
 18. The structural support of claim 17, wherein the gas is air.
 19. The structural support of claim 17, wherein the at least one fillable support tube comprises a deflation valve for allowing deflation of the at least one fillable support tube.
 20. The structural support of claim 17, wherein the at least one fillable support tube is filled to a pressure of approximately 15 psi or less.
 21. The structural support of claim 17, wherein the at least one fillable support tube is filled to a pressure of approximately 5 psi or less.
 22. The structural support of claim 17, wherein the structural support comprises a plurality of fillable support tubes inserted within the support sleeve.
 23. The structural support of claim 22, further comprising: a common fill port for filling the plurality of fillable support tubes with gas; and at least one gas pathway configured to connect at least one fillable support tube to the common fill port.
 24. The structural support of claim 23, wherein the at least one gas pathway is configured to connect a plurality of fillable support tubes to the common fill port.
 25. The structural support of claim 23, wherein the structural support further comprises at least one check valve configured to prevent a pressure loss in one fillable support tube from causing pressure loss in another fillable support tube via the gas pathway.
 26. The structural support of claim 17, further comprising a source of pressurized gas to fill the at least one fillable support tube.
 27. The structural support of claim 26, wherein the source of pressurized gas is an inflator configured to maintain a gas pressure within the at least one fillable support tube.
 28. An inflatable shelter assembly, comprising at least one modular structural section, wherein the at least one modular structural section comprises: a support sleeve; and a plurality of fillable support tubes inserted within the support sleeve. 